Methods of production of textile yarns



my H, 1956 .J. N. HIENSCH METHODS OF PRODUCTION OF TEXTILE YARNS Filed Sept. 11, 1951 2 Sheets-Shes 1; l

I N VEN TOR:

ATTORNEYS.

J. N. HIENSCH 2,743,573

METHODS OF PRODUCTION OF TEXTILE YARNS Filed Sept. 11., 1.951 2 Sheets-Sheet 2 BY M G W/Z.

A TTORNEYS.

United States METHODS OF PRODUCTION G'F TEXTILE YARN Johannes Nathanael Hiensch, Swarthmorc. Pa, to Textile Machinery Corporation, i a corporation of Delaware This invention relates to methods of producing yarns from natural and/ or synthetic fibers.

By the methods ordinarily employed heretofore in the production of textile yarns, it was difficult to control accurately the quantity of fibers incorporated in the individual strands, with the result that reliable uniformity in the diameter of the yarns was unattainable. Moreover, there was a limit with regard to the extent to which fiber slivers could be drawn under the prior art methods. Con sequently the production of very fine yarns has in the past been relatively difficult and therefore expensive.

My invention is directed toward overcoming the above mentioned drawbacks, that is to say: I aim to make possible the commercial production, more expeditiously and economically, of textile yarns of any desired nominal diameter with a high degree of uniformity. This objective is realized in practice, as hereinafter more fully disclosed, through provision of an improved method which comprises the steps of first forming, from a suitable adhesive, foundation strand or strands; then applying natural fibers of cotton, flax, silk, wool, or synthetic fibers of rayon, nylon or the like or blends of such fibers in excess quantity to the strand or strands; and then removing from the strand or strands the excess non-adhering fibers after setting of the adhesive and at the same time aligning those fibers which are attached to the adhesive. In some instances, I may resort to the additional steps of drawing and/or twisting the strand or strands, after appiication of the fibers, to the diameter desired in the finished yarns. In other instances, I may fuse or otherwise soften the adhesive during twisting or after twisting to permanentize the coils resulting from the twisting. Depending upon the type of adhesive employed, the foundation substance may be either entirely or partly dissolved out or other wise removed from the finished yarns, or it may be permanentized and allowed to remain. Alternatively, the adhesive may be removed either before or after the yarns have been woven or knitted into fabric.

Various kinds of fluid adhesives, or substances capable of being rendered fluent and adhesive by application of eat or by treatment with suitable solvents, can be utilized to serve for the foundation strands in accordance with my invention. Amongst such materials are:

A. Water-soluble solutions of starch, glue, viscous gums, resins, alginates and the like, which can be made insoluble by chemical treatment or otherwise after the formation of the yarns.

B. Substances of the gelatin group which can be made fluent and adhesive by fusion under heat and of which some can be made insoluble in water by treatment with formaldehyde after the formation of the yarns.

C. Substances of the casein group which, like the gelatin group, can be made insoluble after formation of the yarns by treatment with formaldehyde. 7

D. Rubber latex or synthetic rubbers which are soluble in benzine and which can be made strong and insoluble by vulcanization.

E. Thermo-plastics such as cellulose acetate which disatent U" 2,743,573 Patented May 1, 1956 solves in acetone or are fusible by heating, and which can be made stronger by stretching.

F. Thermo-setting plastics which, like urea formaldehyde, are water soluble, and which, after the formation of the yarns, can be made strong and insoluble in water by curing through heat treatment.

Substances such as nylon adhesive available in powder form which can be dissolved in alcohol, which after formation of the yarns can be made insoluble by curing, and which can be made stronger by drawing.

Other objects and attendant advantages will appear from the following detailed description of the attached drawings, wherein:

Fig. 1 is a more or less diagrammatic view in longitudinal section, of an apparatus suitable for the practice of my improved method of commercial textile yarn production.

Fig. 2 is a fragmentary sectional view corresponding to Fig. l, drawn to a larger scale and showing to better advantage, important structural details of the apparatus.

Fig. 3 is a fragmentary detail view in cross section taken as indicated by the angled arrows III-4H in Fig. 1, and likewise drawn to a larger scale.

Fig. 4 is an enlarged cross section of a foundation strand as it appears after application thereto of the fibers, the section being taken as indicated by the angled arrows 'iV---lV in Pig. 1.

Fig. 5 is a greatly magnified view showing a fragment of twisted yarn produced in accordance with my invention.

Fig. 6 shows a cross section of the yarn of Fig. 5.

Fig. 7 is a view like Pig. 1 showing an apparatus suitable for the practice of an alternative method of yarn production in accordance with my invention; and

Fig. 8 is a cross section taken as indicated by the angled arrows Xi--Xl in Fig. 7 of the yarn produced with the last mentioned apparatus.

Referring first to the apparatus illustrated in Figs. 1-3 of the drawings, the numeral 15 designates a horizontallyarranged cylinder which in practice is provided with a smooth polished metallic surface which may consist of chromium or the like wherefrom the adhesive used in the processing will readily separate after setting, said cylinder being driven at a constant speed in the direction of the arrow by suitable means not shown. Disposed along one side of cylinder 15 is a manifold pipe 16 having, at intervals iengthwise thereof, a plurality of closely-spaced nozzles, such as the one indicated at 17, which extends into close proximity with the revolving surface of the cylinder. At one end, the manifold pipe in is connected to a gravitydischarge receptacle 13 containing a supply of the adhesive which in this instance may be of either of the groups B, C, E and F supra, some of which must be heated for conversion into a fluent state, said receptable being provided accordingly with a heating coil 19. For the purpose of heat conservation, the manifold pipe 16 and the receptacle are surrounded by jacketing 2b of insulation. The outlets of the nozzles 17 are of narrow fiat configuration so that continuous, thin, fiat adhesive foundation strands S uniform in cross section are deposited on the revolving surface of cylinder 15 as shown. As the strands S pass up the rising side of cylinder 15", a layer or mat M containing an excess quantity of textile fibers is discharged upon said strands. Such mat may be in the form of a single sheet or it may comprise a web or plurality of webs delivered directly from a carding machine or comber, or as shown, from a hopper 21 by action of a pair of cooperative feed rolls 22 within. said hopper. Somewhat further along in the travel of the strands S, the fiber mat M is compacted by a press roll 23, having a covering of rubber or felt, whereby some of the fibers are pressed into said strands. At the very top of cylinder masses is a coolingmeans which is conventionally indicated at and by which the adhesive of the foundation, strands S is set. After traversing the setting means 25, the excess non-adhering textile fibers are removed from the strands byv a revolving brush 26 within a hood 27Wl'll0l'l is connected, by a conduit 28, to a source of suction, not shown. By the action. of brush 26, the adhering fibers are alignedv more or less intne direction of the strands S. Due to setting of the adhesive by the means 25, the strands S readily leave the surface of cylinder 15 under the pull of the draft rolls indicated at 29, by which latter the strands are drawn. to the diameter desired in the finished yarns. In some instances I may dispense with drafting altogether. and employ the rolls 29 merely as a means for advancing the strands. Upon leaving the draft rolls 29, the strands are twisted, inthis instance, by passage through guide eyes 30 enroute to the travellers 31 of a spinning machine where they are collected on the revolving bobbinsv 32 of said machine. The thickness of the foundation strands S can be predetermined by adjustment of the discharge ends of-the nozzles 17 relative to the surface of cylinder 15. By maintaining a constant rate of rotation of cylinder 15 and a constant rate of deposit of liquid adhesive at 17, adhesive strands of uniform cross section are obtained. The number of fibers retained by, the individual strands is directly related to the cross sectional dimensions of the strands in the thicknesses involved in the practice of this invention, and therefore a uniformity of fiber retention is automatically provided which makes possible the production of the unique finished uniform yarns.

From what has been described in connection with Figs. 1-3, it will be seen that my improved method of textile yarn production, as carried out with the apparatus, comprises the steps of first forming a foundation strand or strands of uniform cross section from a fluent adhesive; then applying textile fibers in excess quantity to the strand or strands; then pressing the fibers into adhesive contact with the strands; then setting the strands; then removing the excess non-adhering fibers; then drawing the strands; and finally twisting the strands into the finished yarns which Will then appear as shown in Figs. 5 and 6. if desired, the process may be practiced without the drawing and twisting steps, in which case the yarns will have the cross section shown in Fig. 4. In either case, the adhesive may be dissolved out or otherwise removed either before or after the yarns arewoven or knitted into fabric. Moreover, if desired the strands may be subjected to another treatment at 34 to soften the adhesive during the twisting for mergence of the coils resulting from the twisting.

The apparatus of Figs. 1-3 may also be employed in the production of yarns with foundation strands formed from thematerials of either of the groups A, D, G and H rendered fluent by admixture with solvents, in which case, the meet the heating coils 19 in the supply receptacle flit are dispensed with. In this case however, instead of a cooling, means, a'heating means is employed at 25 for setting theadhesive after the. brushing, and instead of a heating means, a moistening means is utilized at 34 to softenthe adhesive for mergence of the adhesive. Other- Wise, the'steps of the processing carried out in this apparatus will be exactly the same in sequence as described in the -first; instance, as will also be the results attained.

Here, likewise, thefinal drawing, twisting and the twist permanentizing steps maybe omitted if desired.

In Fig. 7, fluent, adhesive is deposited upon the surface of cylinder 1512 by nozzles 17!: to form plural strands S of; fluent adhesiveas in the first described procedure. Here however, filamentF of nylon or other flexible material are run on to the adhesive strands S immediately before application; of themat M of the textile fibers which is thereupon pressed by-the roller 23b. After setting of the adhesive-by the means 25b, the excess nonadhering textile fibers are removed'by: thebrush 26b and carried ofl'from the-hood=27b through the suction tube 28b 'asvinthe two previously described instances. After the brushing, the strandswill appear ascxaggeratedly shown at S in cross section in Fig. 8, with the filaments F embedded in the adhesive. Here also, drawing and/or twisting, and adhesive removal may be resorted to as final steps in the process.

The fibers used in all three instances may be natural fibers of cotton, flax, wool, etc., or cut synthetic fibers of nylon, rayon, etc., or blends of fibers of either or both types.

My invention is, of course, not to be considered as limited to the use of the adhesives herein suggested by the Way of example, since many others having similar properties may be employed within the scope of the appended claims.

The apparatus herein disclosed constitutes the subject matter of a separate patent application Serial No. 249,304 filed by me on October 2, 1951.

having thus described my invention, I claim:

1. A continuous method of producing textile yarn which comprises the steps of forming a fine foundation strand of fluent tacky carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textile fibers; applying textile fibers in excess quantity to the strand; setting the foundation material of the strand; removing the excess non-adhering fibers from the strand; and twisting the fiber-coated strand into yarn.

2. A method of producing textile yarn which comprises the steps of forming a fine foundation strand of fluent tacky carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textile fibers; applying a mat of textile fibers in excess quantity to the strand; setting the foundation material of the strand; removing the excess non-adhering fibers from the strand; and twisting the fiber coated strand into yarn.

3; A method of producing textile yarn which comprises the steps of forming a fine foundation strand of fluent tacky carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textile fibers; applying a mat of textilefibers in excess quantity to the strand; setting the foundation material of the strand; removing-the excess non-adhering fibers from the strand; twisting the fiber coated strand into yarn; and finally softening the foundation material for mergence of the coils resulting from the twisting.

4. A method of producing textile yarn which cornprises the steps of forming a fine foundation strand of fluent tacky carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textilefibers; applying a mat of textile fibers in excess quantity to the strand; setting the foundation material of the strand; removing the excess nonadheringfibcrs from the strand; twisting the fiber coated strand into yarn; and finally removing the foundation material.

5. A continuous method of concurrently producing multiple textile yarns which comprises the successive steps of forming, in spaced parallel relation, fine plural running foundation strands of fluent teeny carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textile fibers; applying a mat of textile fibers in excess quantity to the multiple running foundation strands; setting the foundation material of the multiple running strands; rcmoving the excess non-adhcring fibers from the multiple running strands; and twisting the individual fiber coated strands into yarns.

6. A continuous method of concurrently producing iultiple textile yarns which comprises the successive steps of formiy-g, in spaced parallel relation, fine plural running foundation strands of fluent tac 1y carrier material of uniform thickness and surface area for capacity to trap and retain a definite constantvquantity of textile fibers; applying a mat of textile fibers in excess quantity to the multiple running foundation strands; setting the foundation material of the strands; removing the excess non-adhering fibers from the multiple strands; twisting the individual fiber coated strands into yarns; and finally softening the foundation strands for mergence of the coils resulting from the twisting.

7. A continuous method of concurrently producing multiple textile yarns which comprises the successive steps of forming, in spaced parallel relation, fine plural running foundation strands of fluent tacky carrier material of uniform thickness and surface area for capacity to trap and retain a definite constant quantity of textile fibers; applying a mat of textile fibers in excess quantity to the multiple running foundation strands; setting the foundation material of the strands; removing the excess non-adhering fibers from the multiple strands; twisting the individual fiber coated strands into yarns; and finally removing the adhesive from the yarns.

References Cited in the file of this patent UNITED STATES PATENTS Matt at al. July 18, 1933 Hopkinson Ian. 16, 1934 Slayter et al Oct. 11, 1938 Radford Feb. 7, 1939 Shaw Aug. 15, 1939 Meston Nov. 19, 1940 Perkins Feb. 24, 1942 Modigliani Nov. 2, 1943 Hall Oct. 30, 1945 McMillin et a1 Nov. 19, 1946 Clarkson Oct. 19, 1948 Egger .Dec. 12, 1950 Honig June 19, 1951 FOREIGN PATENTS Great Britain May 3, 1906 Great Britain May 21, 1925 

1. A CONTINUOUS METHOD OF PRODUCING TEXTILE YARN WHICH COMPRISES THE STEPS OF FORMING A FINE FOUNDATION STRAND OF FLUENT TACKY CARRIER MATERIAL OF UNIFORM THICKNESS AND SURFACE AREA FOR CAPACITY TO TRAP AND RETAIN A DEFINITE CONSTANT QUANTITY OF TEXTILE FIBERS; APPLYING TEXTILE FIBERS IN EXCESS QUANTITY TO THE STRAND; SETTING THE FOUNDATION MATERIAL OF THE STRAND; REMOVING THE EXCESS NON-ADHERING FIBERS FROM THE STRAND; AND TWISTING THE FIBER-COATED STRAND INTO YARN. 